CN113194775B

CN113194775B - Footwear element with locating pegs and method of manufacturing an article of footwear

Info

Publication number: CN113194775B
Application number: CN201980084333.8A
Authority: CN
Inventors: E.A.基尔戈
Original assignee: Nike Innovate CV USA
Current assignee: Nike Innovate CV USA
Priority date: 2018-12-28
Filing date: 2019-11-20
Publication date: 2023-08-29
Anticipated expiration: 2039-11-20
Also published as: EP3902426B1; US20200205516A1; WO2020139486A1; US20230015860A1; US11464287B2; CN113194775A; EP3902426A1

Abstract

An article of footwear includes an upper defining apertures spaced from one another in a first arrangement. A footwear element has pegs spaced from one another in a first arrangement and extending through apertures in an upper. The bolts are fixed on the surface of the vamp. A method of manufacturing an article of footwear includes placing a footwear element between an inner layer of an upper and an outer layer of the upper. The footwear element includes at least one peg extending outwardly toward the outer layer. The method includes inserting a plug through the outer layer such that the plug extends through the outer layer and is exposed at an outer surface of the outer layer. After inserting the pegs of the footwear element through the outer layer of the upper, the pegs are secured to the outer surface of the outer layer.

Description

Footwear element with locating pegs and method of manufacturing an article of footwear

Cross Reference to Related Applications

The present application claims priority from U.S. provisional application No. 62/785963 filed on date 28 of 12 in 2018, the entire contents of which are incorporated herein by reference.

Technical Field

The present disclosure generally includes articles of footwear, methods of manufacturing articles of footwear, and footwear elements for articles of footwear.

Background

Traditionally, placing a shoe on a foot typically requires stretching the ankle opening of the upper with one or both hands and maintaining the rear portion during foot insertion, especially in the case of a relatively soft upper and/or a shoe without a heel counter.

Drawings

The drawings described herein are for illustration purposes only and are schematic in nature and are intended to be illustrative rather than limiting the scope of the present disclosure.

Fig. 1 is a front perspective view of a heel support device.

Fig. 2 is a side perspective view of the heel support device.

Fig. 3 is a medial perspective view of the heel support device.

Fig. 4 is a side elevational view of the heel support device.

Fig. 5 is a side elevational view of the heel support device under load.

Fig. 6 is a side perspective view of the article of footwear, showing the upper prior to insertion into the heel support device of fig. 1.

FIG. 7 is a side perspective view of the article of footwear showing the heel support device inserted through the opening between the inner layer and the outer layer of the upper, with the pegs extending through the apertures in the outer layer.

FIG. 8 is a side perspective view of an article of footwear with an opening between the inner layer and the outer layer closed.

FIG. 9 is a side perspective view of the article of footwear, showing the head of the peg secured to the exterior layer of the upper.

FIG. 10 is a side elevational view of the article of footwear with the foot shown in phantom depressing the heel support device during insertion.

FIG. 11 is a side elevational view of the article of footwear with the foot fully inserted.

FIG. 12 is a partial perspective view of an article of footwear and a tool that heats an end of one of the pins of the heel support device.

Fig. 13 is a perspective view of the tool.

Fig. 14 is a partial cross-sectional view of the tool taken along line 14-14 in fig. 13.

Fig. 15 is a partial perspective view of an article of footwear with the head of the peg secured to the outer surface of the upper by the tool of fig. 12.

Fig. 16 is a partial cross-sectional view of the peg and upper of fig. 15, taken along line 16-16 in fig. 15.

Fig. 17 is a plan view of the mold surface of the tool of fig. 12.

Fig. 18 is a plan view of another mold surface for the tool of fig. 12.

Fig. 19 is a plan view of another mold surface for the tool of fig. 12.

Fig. 20 is a plan view of another mold surface for the tool of fig. 12.

Fig. 21 is a plan view of another mold surface for the tool of fig. 12.

Fig. 22 is a plan view of another mold surface for the tool of fig. 12.

FIG. 23 is a rear partial perspective view of another article of footwear with a heel support device.

FIG. 24 is a flow chart of a method of manufacturing an article of footwear.

Detailed Description

The present disclosure relates generally to footwear elements, such as heel support devices or other elastically deformable structural members, and articles of footwear including the footwear elements, and methods of manufacturing the articles of footwear. The footwear element and upper may have complementary locating features as described herein that enable precise positioning of the footwear element relative to the upper. Additionally, features of the footwear element are used to secure the footwear element to the exterior of the upper, and the method of manufacturing the article of footwear is capable of customizing the aesthetic aspects of these features.

In an example, an article of footwear may include an upper defining apertures spaced from one another in a first arrangement. The footwear element may include pegs that are spaced apart from one another in the first arrangement and extend through apertures in the upper. The peg may be secured to a lateral side of the upper.

In one or more embodiments, the upper may include an interior layer and an exterior layer, and may define a foot-receiving cavity on a medial side of the interior layer. The apertures may extend through the outer layer. The footwear element may be disposed between the inner layer and the outer layer. An inner layer may be disposed between the footwear element and the foot-receiving chamber.

In one or more configurations, each pin may include a shaft portion and a head portion integrally configured with the shaft portion. The shaft portion may extend through one of the apertures of the upper. The head may be bonded to an exterior surface of the upper.

In an aspect, the head may depict at least one of a number, letter, symbol, logo, object, or design, or may have a particular surface texture, or may be a particular color. Furthermore, the pegs need not be identical, as one or more pegs may depict different numbers, letters, symbols, logos, objects, designs, surface textures, or specific colors than one or more other pegs.

In another aspect, the footwear element may be a heel support device that is connected to a heel region of the upper and may include a central portion, a medial portion that extends forward from the central portion on a medial side of the heel support device, and a lateral portion that extends forward from the central portion on a lateral side of the heel support device. The first peg may be integral with and extend outwardly from the central portion. The second peg may be integral with the intermediate portion and extend outwardly from the intermediate portion. The third peg may be integral with and extend outwardly from the lateral portion.

In one or more embodiments, the heel support device, including the central portion, the medial portion, the lateral portion, and the peg, may be a unitary, one-piece component.

In one or more configurations, the heel support device can include a lever and a base. The control lever may have a central section, a medial side arm extending downwardly and forwardly from the central section on a medial side of the heel support device, and a lateral side arm extending downwardly and forwardly from the central section on a lateral side of the heel support device. The base may have a medial base arm connected to a medial side arm of the lever, a lateral base arm connected to a lateral side arm of the lever, and a central section connecting the medial base arm to the lateral base arm. The first peg may extend outwardly from the central section of the lever. The second peg may extend outwardly from the medial side arm of the lever or from the medial base arm. The third peg may extend outwardly from a lateral side arm of the lever or from a lateral base arm.

In one aspect, the control lever may include a series of slats. Each slat in the series of slats may extend in a central section, a medial side arm, and a lateral side arm. The first peg may extend outwardly from one of a series of slats. The fourth peg may extend outwardly from the central section of the base.

In another aspect, the lever may be biased to an unloaded position and may resiliently flex under the application of force to a loaded position in which the lever is closer to the base than in the unloaded position, storing potential energy that returns the lever to the unloaded position upon removal of the application of force. The upper may be coupled to the lever for movement therewith via a first pin. The ankle opening of the upper may extend more rearward and downward when the lever is in the loaded position than when the lever is in the unloaded position. The heel support device stores potential energy, such as elastic and/or spring energy, that returns the lever to the unloaded position when the applied load is removed. As used herein, elastic bending may also be referred to as elastic bending, and elastic deformation or elastic deformation is required. For example, the foot may be pressed down on the lever and slid into the foot-receiving cavity of the attached upper without requiring the use of a hand or any tool to adjust the upper for foot access.

In an example, a method of manufacturing an article of footwear may include placing a footwear element between an interior layer of an upper and an exterior layer of the upper. The footwear element may include at least one peg extending outwardly toward the outer layer. The method of manufacturing may include inserting at least one peg of the footwear element through an outer layer of the upper such that the at least one peg extends through the outer layer and is exposed at an outer surface of the outer layer. The method of manufacturing may further include securing the at least one peg to an exterior surface of the exterior layer after inserting the at least one peg through the exterior layer of the upper.

In one or more configurations, at least one peg may include a plurality of pegs and an outer layer of the upper may include a plurality of apertures. The pegs may be spaced apart from each other in the first arrangement. The holes may also be spaced apart from each other in the first arrangement such that the holes are aligned with the pegs.

In one or more embodiments, securing the at least one peg to the exterior surface of the exterior layer of the upper may include bonding the at least one peg to the exterior surface of the exterior layer. In one aspect, bonding the at least one pin to the outer surface of the outer layer may include pressing a heating tool against an end of the at least one pin at the outer surface of the outer layer to melt the end against the outer surface of the outer layer. For example, the heating tool may be an ultrasonic heating tool.

In one aspect, the heating tool may have a mold surface that shapes the head of the at least one pin at the outer surface of the outer layer, and pressing the heating tool to melt the end may create the head. The method of manufacturing may further comprise selecting the heating tool from a set of heating tools, each heating tool having a mold surface with a different shape depicting at least one of a number, letter, symbol, logo, object or design, or having a different surface texture. In another aspect, selecting the heating tool may respond to a request for a particular shape or particular surface texture of the head. The mold surface of the selected heating tool may have a particular shape. For example, a customer may request a particular shape or surface texture in order to customize their shoe. The customer may also request a head of a particular color and the device used may be a material having a particular color.

In another aspect, placement of the footwear element between the interior layer of the upper and the exterior layer of the upper may be through an opening between the interior layer and the exterior layer. The method of manufacturing may further include closing the opening after placing the footwear element between the interior layer of the upper and the exterior layer of the upper.

In an example, the heel support device may be configured to surround a portion of the foot-receiving cavity at a heel region of the article of footwear. The heel support device may include a lever and a base. The control lever may have a central section, a medial side arm extending downwardly and forwardly from the central section on a medial side of the heel support device, and a lateral side arm extending downwardly and forwardly from the central section on a lateral side of the heel support device. The base may have a medial base arm connected to a medial side arm of the lever, a lateral base arm connected to a lateral side arm of the lever, and a central section connecting the medial base arm to the lateral base arm. The heel support device may include a peg extending outwardly from the heel support device. The first peg may extend outwardly from a central section of the lever, the second peg may extend outwardly from a medial side arm of the lever or from a medial base arm, and the third peg may extend outwardly from a lateral side arm of the lever or from a lateral base arm. The lever may be biased to an unstressed position and may be elastically deformed toward the base under a force applied to the loaded position. The heel support device may store potential energy that returns the lever to the unstressed position when the applied force is removed.

In one or more configurations of the heel support device, the control rod may include a series of slats. Each slat in the series of slats may extend in a central section, a medial side arm, and a lateral side arm. The first peg may extend outwardly from one of a series of slats. In one aspect, the fourth peg may extend outwardly from the central section of the base. In another aspect, a heel support device that includes a lever, a base, and a peg may be a unitary, one-piece component.

In one example, an article of footwear includes an upper that includes at least a first layer of a first material having a first melting temperature, the first layer having an inner surface that faces a foot-receiving chamber formed by the upper and having an outer surface that faces away from the foot-receiving chamber. The article of footwear also includes a footwear element that includes a body and at least one peg. At least one peg has a stem portion and a head portion. The first end of the stem is connected to the body and the head is disposed at the second end of the stem. The body is disposed adjacent the inner surface of the first layer and the head is disposed adjacent the outer surface of the first layer. At least one of the pins includes a second material having a second melting temperature that is lower than the first melting temperature.

In one or more embodiments, the stem and head are a unitary, monolithic structure, and the stem further comprises a second material. Furthermore, the head, stem and body may be of unitary, one-piece construction, the stem and body also comprising the second material. In an aspect, the head may depict at least one of a number, letter, symbol, logo, object, or design.

In one or more configurations, a first layer of the upper may define apertures that are spaced apart from one another in a first arrangement. The at least one peg may comprise a plurality of pegs spaced from one another in the first arrangement and extending through apertures in the upper.

In one aspect, the first layer may be an exterior layer of the upper, and the upper may further include an interior layer with the foot-receiving chamber on a medial side of the interior layer. The apertures may extend through the outer layer. The footwear element may be disposed between the inner layer and the outer layer. An inner layer may be disposed between the footwear element and the foot-receiving chamber.

In another aspect, the footwear element may be a heel support device disposed in a heel region of the upper. The body may include a central portion, a medial portion extending forward from the central portion on a medial side of the heel support device, and a lateral portion extending forward from the central portion on a lateral side of the heel support device. The first peg may be integral with and extend outwardly from the central portion, the second peg may be integral with and extend outwardly from the intermediate portion, and the third peg may be integral with and extend outwardly from the lateral portion.

In another aspect, a heel support device that includes a central portion, a medial portion, a lateral portion, and a peg may be a unitary, one-piece component.

In one or more configurations, the footwear element may be a heel support device that is coupled to a heel region of the upper. The body of the heel support device may include a lever and a base. The control lever may have a central section, a medial side arm extending downwardly and forwardly from the central section on a medial side of the heel support device, and a lateral side arm extending downwardly and forwardly from the central section on a lateral side of the heel support device. The base may have a medial base arm connected to a medial side arm of the lever, a lateral base arm connected to a lateral side arm of the lever, and a central section connecting the medial base arm to the lateral base arm. The first peg may extend outwardly from a central section of the lever, the second peg may extend outwardly from a medial side arm of the lever or from a medial base arm, and the third peg may extend outwardly from a lateral side arm of the lever or from a lateral base arm.

In one or more embodiments, the control lever may include a series of slats. Each slat in the series of slats may extend in a central section, a medial side arm, and a lateral side arm. The first peg may extend outwardly from one of the series of slats and the fourth peg may extend outwardly from the central section of the base. The lever may be biased to an unloaded position and may be resiliently flexed to a loaded position under the application of force, in which the lever is closer to the base than in the unloaded position, storing potential energy that returns the lever to the unloaded position upon removal of the application of force. The upper may be coupled to the lever for movement therewith via a first pin. The ankle opening of the upper may extend more rearward and downward when the lever is in the loaded position than when the lever is in the unloaded position.

In one example, an article of footwear includes an upper having at least a first layer of pliable material disposed about at least a portion of a foot-receiving cavity. The article of footwear also includes an elastically deformable structural member disposed on a first side of the first layer proximate the foot-receiving chamber. The article of footwear also includes a peg extending from a first end connected to the elastically deformable structural member to a distal end spaced apart from the elastically deformable structural member. The peg extends through an aperture provided in the first layer to the second side of the first layer. A widened head is disposed at the distal end of the peg. The width of the widened head is greater than the width of the aperture.

In one example, a method of manufacturing an article of footwear includes obtaining a footwear element having a stud including a shank, and extending the shank through and protruding from a first layer of an upper. The method of manufacturing further includes forming a head at an end of the stem after the stem protrudes from the first layer.

In one or more embodiments, forming the head bonds the head to the first layer. Forming the head may include melting an end of the stem. Forming the head may include pressing a heating tool against an end of the stem to melt the end.

In one or more constructions, the heating tool may have a mold surface that shapes the head, and the method of manufacturing may further include selecting the heating tool from a set of heating tools, each heating tool having a mold surface with a different shape that depicts at least one of a number, letter, symbol, logo, object, or design, or having a different surface texture.

In one aspect, selecting the heating tool may respond to a request for a particular shape or particular surface texture of the head. The mold surface of the selected heating tool may have a particular shape or a particular surface texture as requested.

In another aspect, the head may protrude through an aperture in the first layer, and the head may be larger than the aperture.

In one or more embodiments, the upper may further include a second layer, and the method may further include placing the footwear element between the first layer and the second layer prior to forming the head.

In one aspect, placement of the footwear element between the first layer and the second layer of the upper may be through an opening between the first layer and the second layer. The method of manufacturing may further include closing the opening after placing the footwear element between the first layer and the second layer.

The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the modes for carrying out the present teachings when taken in connection with the accompanying drawings.

Referring to the drawings, wherein like reference numbers refer to like components, FIG. 1 shows a footwear element 10 that is an elastically deformable structural member of an article of footwear. The footwear element 10 shown and described herein is a heel support device and may be referred to herein as such. In other embodiments, other footwear elements may be constructed and/or manufactured in accordance with the teachings herein. The heel support device 10 facilitates foot access to an article of footwear as described herein. Heel support device 10 is also referred to herein as device 10 or heel spring device 10. The device 10 includes pegs 12 that serve as locating features for precisely locating the device 10 relative to the upper during manufacturing, as described herein. In the embodiment shown, there are four pegs 12, only three of which are visible in fig. 1.

The heel support device 10 has a central section 14, a medial side arm 16, and a lateral side arm 18. The medial side arm 16 extends downwardly and forwardly from the central section 14 at a medial side 20 of the heel support device 10. The lateral side arms 18 extend downwardly and forwardly from the central section 14 at lateral sides 22 of the heel support device 10. The central section 14, the medial side arm 16, and the lateral side arm 18 are collectively referred to as a control lever 24.

The base 26 supports the control lever 24 and is connected to the control lever 24 at elastically bendable joints 25A, 25B. The base 26 is continuous and extends between the medial side arm 16 and the lateral side arm 18 and is connected to the medial side arm 16 and the lateral side arm 18. The base 26 is continuous in that it does not break or connect through other components as it extends from the medial side arm 16 to the lateral side arm 18.

The base 26 has a toothed inner edge 28. In other words, the inner edge 28 includes a series of notches 30. The base 26 has a cup shape and extends to an inner edge 28 below the sole of the foot. More specifically, the device 10 has an inner surface 32 with a first recess from the medial side arm to the lateral side arm and a second recess from the upper portion of the central section 14 to the inner edge 28 of the base 26. The recess 30 at the inner edge 28 provides a more gradual feel of stiffness change from the relatively hard and firm heel support device 10 to the relatively soft underlying sole structure while still providing sufficient bonding area of the underside of the base to the sole structure or shoe sole.

The base 26 has a medial base arm 34 (best shown in fig. 3) connected to the medial side arm 16 of the lever 24 and a lateral base arm 36 connected to the lateral side arm 18 of the lever 24. The base 26 also includes a central section 38 that connects the medial base arm 34 to the lateral base arm 36. The central section 38 of the base 26, the medial base arm 34, and the lateral base arm 36 are disposed in a common plane. The common plane is parallel to the horizontal surface when the base 26 of the device 10 rests on the horizontal surface. The medial base arm 34 is spaced apart from the lateral base arm 36 and extends from a central section 38 of the base 26.

The central sections 14, 38 may be referred to together as the central portion of the device 10, the medial side arm 16 and the medial base arm 34 may be referred to together as the medial portion of the device 10, and the lateral side arm 18 and the lateral base arm 36 may be referred to together as the lateral portion of the device 10. In the embodiment shown herein, the device 10 is configured as a heel spring device, the lever 24 being movable toward the base 26, and configured to facilitate easy entry and removal of a foot from an article of footwear, as described herein. In other embodiments, the device may be a U-shaped heel counter without a lever or base, primarily for supporting the heel area, and not requiring easy access. In other embodiments, instead of a heel support device, footwear element 10 may be an elastically deformable structural member that may facilitate easy access to the foot-receiving chamber, or may have a structural purpose that is different from easy access.

The joints 25A, 25B include a first joint 25A where the base 26 is connected to the medial side arm 16 and a second joint 25B where the base 26 is connected to the lateral side arm 18. The first joint 25A is a connection of the intermediate base arm 34 to the intermediate side arm 16. The second joint 25B is the connection of the lateral base arm 36 to the lateral side arm 18.

The control lever 24 is arcuate from a first joint 25A to a second joint 25B. Similarly, the base 26 is arcuate from the first joint 25A to the second joint 25B. With this arrangement, the control lever 24 and base 26 are constructed as a full oval leaf spring as described herein, and the device 10 may be referred to as a heel spring device.

The control lever 24 includes a series of slats 24A, 24B, 24C and 24D. Each slat 24A, 24B, 24C, and 24D in the series of slats extends in the central section 14, the medial side arm 16, and the lateral side arm 18. Thus, each slat 24A, 24B, 24C, and 24D is part of the central section 14, is part of the medial side arm 16 extending from the central section 14 to the base 26 at the medial side 20, and is part of the lateral side arm 18 extending from the central section 14 to the base 26 at the lateral side 22.

The lever 24 defines a slot 40 extending between the slats 24A, 24B, 24C and 24D. When the lever 24 is in the unloaded position shown in fig. 2, the slats 24A, 24B, 24C and 24D are spaced apart from each other by the slot 40. The pegs 12 are spaced apart from each other in the first arrangement. The first arrangement is the relative spacing of the pegs 12 (e.g., the distance between different pegs 12) as shown in fig. 1-3 when the device 10 is in the unloaded position. The first peg 12A is integral with and extends outwardly from one of the slats 24B at the central section 14. The second peg 12B is integral with the intermediate portion and extends outwardly therefrom. The second peg 12B is shown extending outwardly from the intermediate base arm 34. In another embodiment, the second peg 12B may be integral with and extend from one of the slats 24A, 24B, 24C, 24D at the medial side arm 16. The third peg 12C is integral with the lateral portion and extends outwardly therefrom. The third peg 12C is shown extending outwardly from the lateral base arm 36. In another embodiment, the third peg 12C may be integral with and extend from one of the slats 24A, 24B, 24C, 24D at the lateral side arm 18. The fourth peg 12D extends outwardly from the central section 38 of the base 26.

In fig. 1-3, the device 10 is shown prior to final assembly in an article of footwear. At a stage prior to final assembly as shown, the peg 12 is a generally straight cylindrical shaft extending to a distal end with a constant width. Although four pegs 12 are shown, the device 10 may have fewer or more pegs. Providing at least two spaced apart pegs 12 provides some ability to precisely position the device 10 relative to the upper during manufacturing. By providing four pegs 12, one peg 12A on the lever 24, one peg 12D on the base 26, one peg 12B on the medial base arm 34, one peg 12C on the lateral base arm 36, the four pegs 12 are arranged in a first arrangement, i.e., four spaced apart points, not all of which are coplanar. This locates device 10 more precisely relative to the upper during manufacturing than just two or three pegs.

Furthermore, the heel support device 10, including the control rod 24, the base 26, and the peg 12, is a unitary, one-piece component, wherein the control rod 24, the base 26, and the peg 12 are all made of the same material. For example, the device 10 may be injection molded as a single, unitary, one-piece component. The control lever 24 and the base 26 may be referred to as the bodies 24, 26 of the device 10, and the peg 12 is connected to the bodies 24, 26, such as by Is integral with the bodies 24, 26. The material of the device 10, and in particular the material of the bodies 24, 26, is selected to provide the ability to elastically deform by elastic bending as described above, and to store potential energy, such as elastic energy, that returns the device 10 to the unloaded position. The head material of the pin 12 may be the same material as the bodies 24, 26, which is selected to provide a lower melting temperature than the melting temperature of the footwear layer in which the pin head is disposed or at least the head of one of the pins is disposed, as described herein. Exemplary materials for the device 10 include plastics (such as thermoplastics), composites, and nylons. Another exemplary material for device 10 is a polyether block amide, such as that available from Arkema corporation of King of Prussia, pennsylvania USAAnother example material for the device 10 is fiberglass reinforced polyamide. Exemplary glass fiber reinforced polyamides are +.A.A. available from Arkema company of King of Prussia, pennsylvania USA>The glass fiber reinforced polyamide had a density of 1.07 g/cc in the ISO 1183 test method, an instantaneous hardness of 75 on the shore D scale in the ISO 868 test method, a tensile modulus of 1800MPa in the ISO 527 test method (sample treated at 23 degrees celsius and 50% relative humidity for 15 days), and a flexural modulus of 1500MPa in the ISO 178 test method (sample treated at 23 degrees celsius and 50% relative humidity for 15 days). Another example material for device 10 is nylon 12 (with or without fiberglass), such as RTP 200F or RTP 201F available from RTP company of winena, minnesota USA. Another example material for device 10 is a rigid thermoplastic polyurethane (with or without fiberglass), such as RTP 2300 or RTP 2301 available from RTP company of Winona, minnesota USA. Another example material for the device is acetal (polyoxymethylene) (POM) (with or without glass fibers), such as RTP 800 or RTP 801 available from RTP company of winena, minnesota USA.

Furthermore, the relative size and shape of the device 10 at the joints 25A, 25B and at the medial and lateral side arms 16, 18 contributes to the spring biasing characteristics of the device 10 and its ability to elastically deform and return to its original unloaded position at the desired loading. The device 10 may be configured to flex elastically at a maximum force of 160N. For example, the medial and lateral side arms 16, 18 may each have a thickness that is greater than the width at the respective joints 25A, 25B. The thickness is measured in the fore-and-aft (longitudinal) direction of the shoe. The width is measured in the medial-lateral (transverse) direction of the shoe. The greater thickness increases the force required to resiliently flex the device 10 to the loaded position.

Referring to fig. 4, the lever 24 is biased to the unloaded position. In other words, the material of the device 10 is biased to the unloaded position of fig. 4 by the material in its formed state. The material of the device 10 will resist loading and when the load is removed, the internal stress biases the device 10 back to the unloaded position. The material of the lever 24 is sufficiently rigid that it remains in the unloaded position in its natural state without an external load applied thereto, and will return to the unloaded position after elastic bending due to its elasticity. In the unloaded position, the central section 14 of the lever 24 is farther from the base 26 than in the loaded position of fig. 5.

When the lever 24 is in the unloaded position, the lever 24 extends at a first acute angle A1 to the level of the ground G on which the base 26 rests. The angle A1 may be measured at the lower edge of the lever 24 or along the longitudinal axis of either side arm, or each of the medial side arm 16 and the lateral side arm 18 may have a first acute angle with a different value. In the unloaded position, adjacent slats 24A, 24B, 24C, 24D are spaced apart from one another by slots 40.

Fig. 5 illustrates the device 10 during loading by a force applied downward on the central section 14 of the lever 24 (e.g., the load of the foot during its entry into the foot-receiving cavity of an article of footwear). When the lever 24 is depressed such that the device 10 is in the position of fig. 5, the medial and lateral side arms 16, 18 extend at a second acute angle A2 to the plane of the ground G on which the base 26 rests. The angle A2 may be measured at the lower edge of the lever 24 or along the longitudinal axis of either side arm. As shown in fig. 5, the slot 40 is closed between the slats 24A, 24B, 24C, and 24D such that one or more adjacent slats 24A, 24B, 24C, 24D contact each other in the loaded position. The second acute angle A2 is smaller than the first acute angle A1. The device 10 elastically flexes (e.g., elastically deforms) under the application of a force F to the loaded position of fig. 5, in which the central section 14 of the lever 24 is closer to the base 26 than in the unloaded position, storing potential energy that returns the lever 24 to the unloaded position upon removal of the application of the force F. For example, the foot may be pressed down on the lever 24 and slid into the foot-receiving cavity of the attached upper without requiring the use of a hand or any tool to adjust the upper for foot access.

Fig. 6 shows an article of footwear 50 having an upper 52 and a sole structure 53 prior to insertion and securement of device 10 to upper 52. Footwear 50 is described herein as either a casual shoe or an athletic shoe, but the present teachings also include the following articles of footwear: fashion shoes, work shoes, sandals, slippers, boots or any other kind of shoes.

Upper 52 includes an interior layer 52A and an exterior layer 52B. Upper 52 defines a foot-receiving chamber 54 on a medial side of interior layer 52A and an ankle opening 56 for accessing chamber 54. Inner layer 52A is disposed between foot-receiving chamber 54 and outer layer 52B (e.g., closer to the foot disposed within foot-receiving chamber 54). Upper 52 may be a variety of materials or combinations of materials, such as 4-way stretch nylon fabric, knit structures, or other materials. The material of upper 52 may be flexible to allow upper 52 to move with device 10 during easy entry of a foot into article of footwear 50, as described herein. Exterior layer 52B may be referred to as a first layer of upper 52 and is formed from a first material that has a first melting temperature and a first combustion temperature.

The article of footwear 50 includes a heel region 58, a midfoot region 60, and a forefoot region 62. When a human foot is supported on sole structure 53 in foot-receiving cavity 54 and corresponds in size to article of footwear 50, heel region 58 generally includes a portion of article of footwear 50 corresponding with a rear portion of the human foot, including the calcaneus bone. The forefoot region 62 of the article of footwear 50 generally includes portions of the article of footwear 50 corresponding with the toes and the joints connecting the metatarsals with the phalanges of the human foot (interchangeably referred to herein as the "metatarsophalangeal joints", "metatarsal-phalangeal joints" or "MPJ" joints). Midfoot region 60 of the article of footwear is disposed between heel region 58 and forefoot region 62, and generally includes portions of article of footwear 50 corresponding with the arch region of the human foot, including the navicular joints.

Sole structure 53 includes one or more sole elements that may be a sole layer, such as an outsole, a midsole, or a unitary combination of an outsole and a midsole, which may be referred to as a unitary sole. A lower portion of upper 52 may be secured to sole structure 53, such as by adhesive or other means, and/or may be stitched or otherwise secured to a receptacle, which in turn is secured to a sole layer.

The outer layer 52B of the upper 52 has apertures 64A, 64B, 64C, and 64D that are arranged relative to one another in the same first arrangement as the pegs 12 of the device 10, and thus may serve as complementary locating features for the pegs 12. Aperture 64A is located in the rear of heel region 58, relatively high on upper 52. Aperture 64B is located on medial side 70 of article of footwear 50. Aperture 64C is located on lateral side 72 of article of footwear 50. Aperture 64D is located at the rear of heel region 58, relatively low on upper 52 such that it is closer to sole structure 53 than aperture 64A, and is generally vertically aligned with (e.g., directly below) aperture 64A. The holes 64A and 64D are spaced apart from each other at the same spacing as the pegs 12A and 12D (e.g., the distance between the holes 64A, 64D). The holes 64B and 64C are spaced apart from each other at the same spacing as the pegs 12B, 12C (e.g., the distance between the holes 64B, 64C). Holes 64B and 64C are also spaced from holes 64A and 64D at the same spacing as pegs 12B and 12C are spaced from pegs 12A and 12D. Holes 64A, 64B, 64C, and 64D extend through outer layer 52B as through holes. Inner layer 52A need not have apertures for attaching device 10 within article of footwear 50.

As shown in FIG. 6, at this stage of manufacture, lower edge 66 of inner layer 52A is not secured in heel region 58 to create an opening 67 to allow device 10 to be inserted between inner layer 52A and outer layer 52B. In front of heel region 58, inner layer 52A may be stitched or otherwise secured to sole structure 53, a shoe support, or outer layer 52B. The opening 67 extends from a medial side 70 to a lateral side 72 about the rear of the heel region 58.

As shown in fig. 7, inner layer 52A is a pliable material such that it can be lifted at lower edge 66, where it is unsecured to enlarge opening 67, allowing device 10 to fit through opening 67 to rest against the interior of outer layer 52B. In other words, the device 10 is disposed on a first side of the outer layer 52B, i.e., the side proximate the foot-receiving chamber 54 (e.g., the medial side). The device 10 is positioned adjacent to the inner surface 55 of the outer layer 52B, with the inner surface 55 facing the foot-receiving chamber 54. An adhesive may be used to secure the lower surface of base 26 to sole structure 53 and/or the shoe sole. Because the holes 64A, 64B, 64C, and 64D are disposed at the same spacing as the pegs 12A, 12B, 12C, 12D, respectively, the device 10 may be inserted into the opening 67, the pegs 12A, 12B, 12C, 12D extend outwardly toward the outer layer 52B, and the device 10 may be placed against the interior of the outer layer 52B with the holes 64A, 64B, 64C, and 64D aligned with the pegs 12A, 12B, 12C, and 12D. By sliding the flexible outer layer 52B over the pegs 12A, 12B, 12C, and 12D such that the pegs 12A, 12B, 12C, and 12D extend through the outer layer 52B and are exposed at the outer surface 74 of the outer layer 52B (also referred to as the outer surface 74 of the outer layer 52B), the pegs 12A, 12B, 12C, and 12D may be inserted through the holes 64A, 64B, 64C, and 64D, respectively. The outer surface 74 faces away from the foot-receiving cavity 54.

As shown in fig. 8, the opening 67 may then be closed by securing the lower edge 66 of the inner layer 52A to the upper side of the outer layer 52B or shoe or base 26 proximate the recess. With the inner layer 52A secured, the device 10 is disposed between the inner layer 52A and the outer layer 52B. An inner layer 52A is disposed on the medial side of heel support device 10 between heel support device 10 and foot-receiving chamber 54. The device 10 is configured to surround a portion of the foot-receiving cavity 54 at the heel region 58.

In fig. 8, pegs 12A, 12B, 12C, and 12D extend outward of outer layer 52B. However, the diameter of the pegs 12A, 12B, 12C, and 12D is approximately the same or smaller than the diameter of the holes 64A, 64B, 64C, and 64D. To further secure device 10 in place relative to upper 52, pegs 12A, 12B, 12C, and 12D are secured at holes 64A, 64B, 64C, and 64D at an outer surface 74 of outer layer 52B. More specifically, the material at the end of each peg 12A, 12B, 12C, and 12D is melted and shaped to form a head of the peg that is larger than the bore and larger than the remaining shaft portion that extends through the bore. The melted material forms enlarged heads 76 of the pins 12A-12D shown in fig. 9. Enlarged head 76 may also be referred to as a widened head. In some embodiments, the molten material of the enlarged head 76 may bond to the outer surface 74 around the holes 64A, 64B, 64C, 64D as it cools. The formation of the enlarged head 76 of the peg is further described with reference to fig. 12-16. Head 76 may be bonded to outer layer 52B when upper 52 and device 10 are on a last. Sole structure 53 may then be secured to a lower perimeter of upper 52, a shoe support, and/or a bottom side of device 10 proximate recess 30. Alternatively, as shown in fig. 6-9, device 10 may be inserted between the layers of upper 52, and the bonding of head 76 to outer layer 52B may occur after upper 52 has been propped up, secured to sole structure 53 on the last, and removed from the last.

Fig. 10 shows foot 78 shown in phantom exerting a force F on lever 24 of device 10 to move device 10 to the loaded position. Because upper 52 is secured to device 10 at peg 12 by head 76, upper 52 folds downward with device 10 at heel region 58 such that ankle opening 56 extends more rearward and downward when lever 24 is in the loaded position than when the lever is in the unloaded position shown in fig. 11. When the foot 78 is moved forward and downward into the foot-receiving chamber 54, the biasing of the device 10 returns the device 10 to the unloaded position of fig. 11.

Conventionally, sliding a foot into an upper typically requires one or both hands to stretch the ankle opening and maintain the rear portion during foot insertion, particularly in the case of a relatively soft upper and/or an upper that does not have a heel counter secured to the flexible fabric behind the ankle opening. The device 10 alleviates these problems and allows the foot 78 to enter the foot-receiving chamber 54 formed by the upper 52 without the use of hands or other tools. Only the foot 78 is used for entry. Specifically, as shown in FIG. 10, with the bottom of the foot 78, a force F is applied to press against the lever 24, resiliently flexing the device 10 at the joints 25A, 25B, moving the lever 24 from the unloaded position to the loaded position. The outer layer 52B of the upper 52 is attached to the central section 14 of the control rod 24 at the peg 12A and is flexible enough to move downward with the control rod 24. As shown in FIG. 11, when foot 78 is fully moved into foot-receiving chamber 54, the stored elastic energy due to the bias of device 10 automatically returns device 10 to the unloaded position, causing upper 52 to be automatically pulled up over the back of foot 78. The device 10 may also be configured to widen as it moves from the unloaded position to the loaded position. This facilitates easy insertion of the foot 78 into the flexible upper 52 because the medial side arm 16 and the lateral side arm 18 can flex away from each other in the lateral direction when the lever 24 is depressed, pulling the upper 52 attached at the peg 12 outwardly.

The article of footwear 50 is characterized by the absence of a rigid material, such as a rigid heel counter between the lever 24 and the base 26 behind the joints 25A, 25B between the lever 24 and the base 26. The device 10 functions, at least in some respects, as a heel counter in that it helps to maintain the wearer's heel atop the heel region 58 of the sole structure 53, preventing medial or lateral displacement during use.

Fig. 12 shows a tool 80 for melting the material of the end of the pin 12C to form the head 76, as shown in fig. 15. The tool 80 may be, for example, an ultrasonic welding tool that converts electrical power into ultrasonic vibrations that generate sufficient friction to generate heat to cause the material of the pin 12C to melt. Fig. 13 shows a tool 80 powered by a power source 81, such as a battery or an electrical outlet. An example tool 80 is an ultrasonic welding tool available from Dukane iQ ultrasonic welder available from Dukane corporation of Saint Charles, illinois USA.

Tool 80 has an end 82 that forms a mold cavity with a mold surface 86. As shown in fig. 14, the mold cavity 84 is generally hemispherical with a central protrusion 87 in the mold surface 86. Fig. 16 shows a mold cavity 84 and a mold surface 86 forming molten material into a head 76 having a central recess 88. The end 82 has a circular opening 89 to the cavity 84. The diameter of the circular opening 89 is greater than the diameter of the pin 12C before the end of the pin 12C melts. Thus, when the tool 80 is pressed against the outer surface 74, the material of the pin 12C melts and then cools as the tool 80 is de-energized. When the tool 80 is held in place against the outer layer 52B for a predetermined cooling time, the melted material will melt against the outer surface 74 of the outer layer 52B and thereby bond to the outer surface 74 of the outer layer 52B around the hole 64C, as shown at bonding region 90 in fig. 16. The melted material is referred to as a head 76 or widened head. The head 76 extends from the remainder of the original unmelted portion of the pin 12C, which is referred to as the shaft portion 92 or stem portion 92. The shaft portion 92 and the head portion 76 are of unitary, one-piece construction. The shaft portion 92 extends from a first end 93 connected to the base 26 (e.g., the body of the device 10) to a distal end 95 (also shown in fig. 12) spaced from the first end 93, and the distal end 95 protrudes through the outer layer 52B to a second side of the outer layer 52B (e.g., outside at the outer surface 74) at the aperture 64C. Outer layer 52B is flexible enough to allow shaft portion 92 to be inserted through aperture 64C to extend through outer layer 52B such that distal end portion 95 protrudes from outer layer 52B. For example, the outer layer 52B is sufficiently flexible such that the shaft portion 92 may be manually (or by robotic machinery) extended through the first layer 52B. The shaft portion 92 extends through the first layer 52B from a first side of the first layer 52B (e.g., the inner side at the inner surface 55) and protrudes from the first layer 52B at a second side of the outer layer 52B (e.g., the outer side at the outer surface 74). Additionally, in some embodiments, the outer layer 52B may not have preformed holes in the first spacing, but may be flexible enough to allow the shaft portion 92 to stretch or puncture the material of the outer layer 52B. After extending the shaft portion 92 through the first layer 52B and protruding outward, the tool 80 may be held and pressed one at a time against the outer surface 74 of each peg 12 to melt the material of the shaft portion 92 at the distal end portion 95, forming the head 76 at each peg 12. The width W1 of the head portion 76 disposed at the distal end portion 95 is greater than the width W2 of the corresponding hole 64C through which the shaft portion 92 extends.

The outer layer 52B is a first material having a first melting temperature and the material of the pin 12, or at least the distal end 95 of the pin 12, that is melted to form the head 76 is a second material having a second melting temperature that is lower than the first melting temperature. The first material of the outer layer 52B also has a combustion temperature that is higher than the melting temperature of the second material of the pin 12. Thus, melting the material of the plug 12 at the distal end 95 with the tool 80 to form the head 76 does not cause the outer layer 52B to melt or burn, even if the head 76 is bonded to the outer layer 52B.

The head 76 may have various shapes or textures to achieve structural integrity in combination with the outer layer 52B, to achieve a particular aesthetic, or both. For example, the mold cavity 84 and the mold surface 86 affect the final shape of the head 76. Providing a circular opening enables the melted material to bond around the entire perimeter of the hole 64C. The opening 89 may have other shapes such as square, triangular, star-shaped, etc. The mold cavity and mold surface provide a generally hemispherical shape of the head 76. In other embodiments, the outer surface of the head 76 furthest from the outer surface 74 may be substantially flat, such as in the form of a flat head. In addition, the mold surface 86 may have protrusions or depressions that form a shape on the surface of the head 76. Fig. 17 shows a recess or protrusion 94A of reverse number 2 shape that will produce the number 2 on the surface of the head 76. Fig. 18 shows a recess or protrusion 94B of inverted letter C shape that will produce the letter C on the surface of the head 76. Fig. 19 shows a recess or protrusion 94C in the shape of a star object that will create a star on the surface of the head 76. Fig. 20 shows a symbol or logo-shaped recess or projection 94D which will result in the shape of the symbol or logo on the surface of the head 76. Fig. 21 shows the recess and projection 94E in a design that is a face and that will produce an image of that face on the surface of the head 76. Fig. 22 shows recesses or protrusions 94F depicting cross-hatching patterns and textures that would result in cross-hatching patterns and textures on the surface of the head 76.

Depending on the method of manufacturing the article of footwear 50, the heating tools 80 may be selected from a group of tools, each having a differently shaped mold surface 86, depicting at least one of numbers, letters, symbols, logos, objects, designs, and/or each having a different surface texture, examples of which are shown in fig. 15 and 17-22. Selection of a particular heating tool may be responsive to a request for a head 76 having a particular shape or surface texture. The mold surface 86 of the selected heating tool 80 may have a particular shape or surface texture. The final head 76 of the peg 12 made with the selected heating tool 80 will then have the particular shape requested, which may depict at least one of a number, letter, symbol, logo, object or design, or the particular surface texture requested. The request may also be of a particular color for the head 76, and the device 10 may be manufactured from a material having the particular color requested. Additionally, the pegs 12 need not be identical, and the request may include one or more pegs 12 depicting a different number, letter, symbol, logo, object, design, or different surface texture or color than one or more other pegs 12.

In some embodiments, the upper may have multiple outer layers (e.g., layers on the outside of device 10), and pegs 12 may extend through some or all of these outer layers. For example, FIG. 23 illustrates a rear portion of another article of footwear 150. Article of footwear 150 has an upper 152 that includes a plurality of exterior layers. Upper 152 includes an interior layer 52A and an exterior layer 52B. In addition, upper 152 includes an exterior layer 52C that is secured to exterior layer 52B. Outer layer 52C also has holes 164A aligned with holes 64A of outer layer 52B. The pin 12A extends through both holes, the head 76 of the pin 12A is melted to form the head 76 disposed at the outer surface 174C, and the head 76 may be secured against (e.g., bonded to) the outer surface 174C of the outer layer 52C. Similarly, on lateral side 72, peg 12C extends through hole 164C in outer layer 52D and hole 64C in outer layer 52B (see fig. 6) such that head 76 is disposed at outer surface 174D and may be secured to outer surface 174D of outer layer 52D. The head 76 of the peg 12B is similarly disposed at the intermediate side 70 at an aperture 164B in the outer layer 52D that is aligned with the aperture 64B. In contrast, the head 76 of the pin 12D is disposed at and possibly coupled to the outer surface 174B of the outer layer 52B, as shown in fig. 9, with the outer layer 52D extending over and covering the head 76 of the pin 12D. The outer layer 52D protects the head 76 of the plug 12D. The head 76 of the peg 12D may alternatively be disposed on a lower portion of the article of footwear 150 such that it is covered by a rear portion of the sole structure 53. In either case, the head 76 may have a hemispherical shape created by the mold cavity 84, or may have other shapes. For example, head 76 may have a generally planar outer surface, such as the outer surface of a planar stud, to minimize distortion of outer layer 52D or sole structure 53.

Fig. 24 is a flow chart of a method of manufacturing an article of footwear, such as article of footwear 50 or article of footwear 150, described herein, and is referred to as manufacturing method 200. The method of manufacturing 200 is described with respect to the article of footwear 50. The method begins at step 201 with obtaining a footwear element, such as a heel support device 10, having a peg 12 and a stem (e.g., shaft portion 92). Manufacturing method 200 may then proceed to step 202, where a heel support device is placed between the inner layer and the outer layer of the upper. For example, step 202 may be performed by placing heel support device 10 between inner layer 52A and outer layer 52B of upper 52. Once the device is placed between layers 52A, 52B, the method moves to step 204 such that shank 92 extends through and protrudes from the first layer (exterior layer 52B) of upper 52 (e.g., at exterior surface 74), such as by inserting a peg extending outwardly from the heel support device between the interior and exterior layers. For example, the pegs 12 of the heel support device 10 may be inserted through the holes 64A, 64B, 64C, and 64D in the outer layer 52B. The holes 64A, 64B, 64C, and 64D may all be arranged in a first arrangement (e.g., they all have the same relative spacing).

In addition, the method of manufacturing 200 may enable the head 76 of the peg 12 to be customized. For example, in step 206, the manufacturer may receive a request for a heel support device having one or more heads with a particular shape, a particular surface texture, and/or a particular color. The request may be for a particular shape of one or more heads 76 of heel support device 10, such as a shape depicting at least one of a number, letter, symbol, logo, object, design, or for a head 76 having a particular surface texture, or for a head 76 having a particular color, as described herein. The request may be received directly from a consumer purchasing the article of footwear 50, or may be received from an entity selling the article of footwear 50 to the consumer. In response to the request received in step 206, the manufacturer may then select a particular heating tool having a mold surface with the particular shape or surface texture requested, such as by selecting a particular heating tool 80 for heel support device 10, and if a particular color is requested, a particular color of material may be used for the heel support device.

After step 208, or without steps 206 and 208, then directly after step 204, the method 200 of manufacturing moves to step 210, wherein the head 76 of the peg 12 is formed at the outer surface of the outer layer. For example, step 210 may be accomplished according to substep 212, wherein the heating tool 80 is pressed against the distal end 95 of each pin 12 at the outer surface 74 to melt the distal end 95 to form the head 76. When melted, the melted end (e.g., head 76) may also be bonded to the outer surface 74 of the outer layer 52B, thereby bonding the pin 12 to the outer surface 74 of the outer layer 52B.

Manufacturing method 200 may also include step 214 of closing the opening between the inner and outer layers through which the heel support device is inserted in step 202, such as by closing opening 67 between inner layer 52A and outer layer 52B. Step 214 occurs after steps 202 and 204, and may occur before or after steps 206 and 208.

The following clauses provide example constructions of the articles of footwear, heel support devices, and methods of manufacture disclosed herein.

Clause 1: an article of footwear, comprising: an upper defining apertures spaced apart from one another in a first arrangement; a footwear element having pegs spaced from each other in a first arrangement and extending through apertures in the upper; and wherein the peg is secured to a surface of the upper.

Clause 2: the article of footwear of clause 1, wherein: the upper including an interior layer and an exterior layer, and defining a foot-receiving cavity on a medial side of the interior layer; the aperture extends through the outer layer; the footwear element is disposed between the inner layer and the outer layer; the inner layer is disposed between the footwear element and the foot-receiving chamber.

Clause 3: the article of footwear of clause 1 or clause 2, wherein: each pin includes a shaft portion and a head portion integrally constructed with the shaft portion; the shaft portion extends through a hole of the upper; and the head is bonded to the surface of the upper.

Clause 4: the article of footwear of clause 3, wherein the head depicts at least one of a number, letter, symbol, logo, object, or design.

Clause 5: the article of footwear of clause 1 or clause 2, wherein the footwear element is a heel support device connected to a heel region of the upper, and comprising: a central portion, a medial portion extending forward from the central portion on a medial side of the heel support device, and a lateral portion extending forward from the central portion on a lateral side of the heel support device; wherein a first peg is integral with and extends outwardly from the central portion, a second peg is integral with and extends outwardly from the intermediate portion, and a third peg is integral with and extends outwardly from the lateral portion.

Clause 6: the article of footwear of clause 5, wherein the heel support device including the central portion, the medial portion, the lateral portion, and the peg is a unitary, one-piece component.

Clause 7: the article of footwear of clause 5, wherein: the heel support device comprises a control rod and a base; the control lever has a central section, a medial side arm extending downwardly and forwardly from the central section on a medial side of the heel support device, and a lateral side arm extending downwardly and forwardly from the central section on a lateral side of the heel support device; the base has a middle base arm connected to the middle side arm of the control lever, a lateral base arm connected to the lateral side arm of the control lever, and a center section connecting the middle base arm to the lateral base arm; the first peg extends outwardly from the central section of the lever, the second peg extends outwardly from the medial side arm of the lever or from the medial base arm, and the third peg extends outwardly from the lateral side arm of the lever or from the lateral base arm.

Clause 8: the article of footwear of clause 7, wherein: the control lever comprises a series of slats; each slat in the series of slats extends in a central section, a medial side arm, and a lateral side arm; a first peg extends outwardly from one of the series of slats and a fourth peg extends outwardly from the central section of the base.

Clause 9: the article of footwear of any of clauses 7-8, wherein: the lever is biased to an unloaded position and resiliently flexes under the application of force to a loaded position in which the lever is closer to the base than in the unloaded position, storing potential energy that returns the lever to the unloaded position upon removal of the application of force; the vamp is connected with the control rod through a first bolt so as to move together; and the ankle opening of the upper extends more rearward and downward when the lever is in the loaded position than when the lever is in the unloaded position.

Clause 10: a method of manufacturing an article of footwear, the method comprising: placing a footwear element between an interior layer of the upper and an exterior layer of the upper; wherein the footwear element includes at least one peg extending outwardly toward the outer layer; inserting at least one peg of the footwear element through the outer layer of the upper such that the at least one peg extends through the outer layer and is exposed at an outer surface of the outer layer; and securing the at least one peg to an outer surface of the exterior layer after inserting the at least one peg of the footwear element through the exterior layer of the upper.

Clause 11: the manufacturing method of clause 10, wherein: at least one peg includes a plurality of pegs, and an outer layer of the upper includes a plurality of apertures; the pegs are spaced apart from each other in the first arrangement; and the holes are spaced apart from each other in the first arrangement such that the holes are aligned with the pegs.

Clause 12: the method of manufacturing clause 10, wherein securing the at least one peg to the outer surface of the outer layer comprises bonding the at least one peg to the outer surface of the outer layer.

Clause 13: the method of manufacturing clause 12, wherein bonding the at least one peg to the outer surface of the outer layer comprises: the heating means is pressed against the end of at least one pin at the outer surface of the outer layer to melt the end against the outer surface of the outer layer.

Clause 14: the method of manufacturing of clause 13, wherein the heating tool has a mold surface that forms a head of the at least one pin at an outer surface of the outer layer, said pressing the heating tool to melt the end portion to produce the head; and the manufacturing method further comprises: the heating tools are selected from a set of heating tools, each having a mold surface with a different shape depicting at least one of a number, letter, symbol, logo, object, or design, or having a different surface texture.

Clause 15: the method of manufacturing of clause 14, wherein selecting the heating tool is responsive to a request for a specific shape or a specific surface texture of the head; and wherein the mold surface of the selected heating tool has a particular shape or a particular surface texture as desired.

Clause 16: the method of manufacturing of any of clauses 10-15, wherein the placement of the footwear element between the interior layer of the upper and the exterior layer of the upper is through an opening between the interior layer and the exterior layer; and the manufacturing method further comprises: after the footwear element is placed between the inner layer and the outer layer, the opening is closed.

Clause 17: a heel support device for an article of footwear, the heel support device comprising: a lever and a base, both configured to surround a portion of the foot-receiving cavity at a heel region of the article of footwear; wherein the control lever has a central section, a medial side arm extending downwardly and forwardly from the central section on a medial side of the heel support device, and a lateral side arm extending downwardly and forwardly from the central section on a lateral side of the heel support device; wherein the base has a middle base arm connected to the middle side arm of the control lever, a lateral base arm connected to the lateral side arm of the control lever, and a center section connecting the middle base arm to the lateral base arm; wherein the heel support device comprises a peg extending outwardly from the heel support device, including a first peg extending outwardly from a central section of the control lever, a second peg extending outwardly from a medial side arm or a medial base arm of the control lever, and a third peg extending outwardly from a lateral side arm or a lateral base arm of the control lever; and wherein the lever is biased to the unstressed position and elastically deforms toward the base under the force applied to the loaded position, and the heel support device stores potential energy that returns the lever to the unstressed position upon removal of the applied force.

Clause 18: the heel support device of clause 17, wherein: the control lever comprises a series of slats; each slat in the series of slats extends in a central section, a medial side arm, and a lateral side arm; and the first peg extends outwardly from one of the series of slats.

Clause 19: the heel support device of clause 18, wherein the fourth peg extends outwardly from the central section of the base.

Clause 20: the heel support device of any of clauses 16-19, wherein the heel support device including the control rod, the base, and the peg is a unitary, one-piece component.

Clause 21: an article of footwear, comprising: an upper including at least a first layer of a first material having a first melting temperature, the first layer having an interior surface facing a foot-receiving cavity formed by the upper and having an exterior surface facing away from the foot-receiving cavity; a footwear element comprising a body and at least one peg having a stem and a head, a first end of the stem being connected to the body and the head being disposed at a second end of the stem; wherein the body is disposed adjacent an inner surface of the first layer and the head is disposed adjacent an outer surface of the first layer; and wherein the at least one pin comprises a second material having a second melting temperature that is lower than the first melting temperature.

Clause 22: the article of footwear of clause 21, wherein the shank and the head are of unitary, one-piece construction, the shank further comprising a second material.

Clause 23: the article of footwear of clause 21, wherein the head, stem, and body are a unitary, one-piece structure, the stem and body also comprising the second material.

Clause 24: the article of footwear of clause 21, wherein the first layer of the upper defines apertures that are spaced apart from each other in the first arrangement; the at least one peg includes a plurality of pegs that are spaced apart from one another in the first arrangement and extend through apertures in the upper.

Clause 25: the article of footwear of clause 24, wherein: the first layer is an outer layer of the upper, the upper further comprising an inner layer, the foot-receiving cavity being inboard of the inner layer; the aperture extends through the outer layer; the footwear element is disposed between the inner layer and the outer layer; the inner layer is disposed between the footwear element and the foot-receiving chamber.

Clause 26: the article of footwear of clause 25, wherein: the footwear element is a heel support device disposed in a heel region of the upper; the body includes a central portion, a medial portion extending forward from the central portion on a medial side of the heel support device, and a lateral portion extending forward from the central portion on a lateral side of the heel support device; wherein a first peg is integral with and extends outwardly from the central portion, a second peg is integral with and extends outwardly from the intermediate portion, and a third peg is integral with and extends outwardly from the lateral portion.

Clause 27: the article of footwear of clause 26, wherein the heel support device including the central portion, the medial portion, the lateral portion, and the peg is a unitary, one-piece component.

Clause 28: the article of footwear of clause 25, wherein: the footwear element is a heel support device that is coupled to a heel region of the upper; the main body of the heel support device comprises a control rod and a base; the control lever has a central section, a medial side arm extending downwardly and forwardly from the central section on a medial side of the heel support device, and a lateral side arm extending downwardly and forwardly from the central section on a lateral side of the heel support device; the base has a middle base arm connected to the middle side arm of the control lever, a lateral base arm connected to the lateral side arm of the control lever, and a center section connecting the middle base arm to the lateral base arm; the first peg extends outwardly from the central section of the lever, the second peg extends outwardly from the medial side arm of the lever or from the medial base arm, and the third peg extends outwardly from the lateral side arm of the lever or from the lateral base arm.

Clause 29: the article of footwear of clause 28, wherein: the control lever comprises a series of slats; each slat in the series of slats extends in a central section, a medial side arm, and a lateral side arm; a first peg extends outwardly from one of the series of slats and a fourth peg extends outwardly from the central section of the base.

Clause 30: the article of footwear of any of clauses 28-29, wherein: the lever is biased to an unloaded position and resiliently flexes under the application of force to a loaded position in which the lever is closer to the base than in the unloaded position, storing potential energy that returns the lever to the unloaded position upon removal of the application of force; the vamp is connected with the control rod through a first bolt so as to move together; and the ankle opening of the upper extends more rearward and downward when the lever is in the loaded position than when the lever is in the unloaded position.

Clause 31: the article of footwear of clause 21, wherein the head depicts at least one of a number, letter, symbol, logo, object, or design.

Clause 32: an article of footwear, comprising: an upper having a first layer of pliable material disposed about at least a portion of the foot-receiving cavity; an elastically deformable structural member disposed on a first side of the first layer proximate the foot-receiving chamber; a pin extending from a first end connected to the elastically deformable structural member to a distal end spaced apart from the elastically deformable structural member; wherein: the peg extends through an aperture provided in the first layer and to a second side of the first layer; the widened head is arranged at the distal end of the peg; and the width of the widened head is greater than the width of the hole.

Clause 33: a method of manufacturing an article of footwear, the method comprising: obtaining a footwear element having a peg comprising a stem; extending the stem through and protruding from the first layer of the upper; and forming a head at an end of the stem after the stem protrudes from the first layer.

Clause 34: the method of clause 33, wherein forming the head bonds the head to the first layer.

Clause 35: the method of any of clauses 33-34, wherein forming the head includes melting an end of the stem.

Clause 36: the method of any of clauses 33-35, wherein forming the head comprises pressing a heating tool against an end of the stem to melt the end.

Clause 37: the method of clause 36, wherein the heating tool has a mold surface that molds the head, and the method of manufacturing further comprises: the heating tools are selected from a set of heating tools, each having a mold surface with a different shape depicting at least one of a number, letter, symbol, logo, object, or design, or having a different surface texture.

Clause 38: the method of manufacturing of clause 37, wherein selecting the heating tool is responsive to a request for a particular shape or a particular surface texture of the head; and wherein the mold surface of the selected heating tool has a particular shape or a particular surface texture as desired.

Clause 39: the method of any of clauses 33-38, wherein the head protrudes through the hole in the first layer and the head is larger than the hole.

Clause 40: the method of manufacturing any of clauses 33-39, wherein the upper further includes a second layer, the method further comprising: the footwear element is placed between the first layer and the second layer prior to forming the head.

Clause 41: the method of manufacturing clause 40, wherein the placing the footwear element between the first layer of the upper and the second layer of the upper is through an opening between the first layer and the second layer; and the manufacturing method further comprises: after placing the footwear element between the first layer and the second layer, the opening is closed.

To assist and clarify the description of various embodiments, various terms are defined herein. The following definitions apply throughout the specification (including the claims) unless otherwise specified. In addition, all references mentioned herein are incorporated by reference in their entirety.

"article of footwear," "article of footwear," and "footwear" may be considered both a machine and a manufacturer. The assembled, ready-to-wear article of footwear (e.g., shoe, sandal, boot, etc.) and the discrete components of the article of footwear (e.g., midsole, outsole, upper component, etc.) are referred to herein, in singular or plural form, or alternatively, as an "article of footwear" prior to final assembly into the ready-to-wear article of footwear.

"a," "an," "the," "at least one," and "one or more" are used interchangeably to indicate the presence of at least one item. A plurality of such items may be present unless the context clearly indicates otherwise. All numerical values (e.g., amounts or conditions) of parameters in this specification are to be understood as being modified in all instances by the term "about" unless otherwise explicitly or clearly indicated by the context (including the appended claims), whether or not "about" actually appears before the numerical value. "about" means that the value allows some slight imprecision (with values close to, near or quite near to, and near to). If the imprecision provided by "about" is not otherwise understood in the art with this ordinary meaning, then "about" as used herein at least refers to variations that may result from ordinary methods of measuring and using such parameters. As used in the specification and the appended claims, a value is considered "approximately" equal to a stated value if it is neither greater than 5% nor less than 5% of the stated value. Moreover, the disclosure of a range is to be understood as specifically disclosing all values and further divided ranges within the range.

The terms "comprises," "comprising," and "having" are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. The order of steps, processes, and operations may be changed when possible, and additional or alternative steps may be employed. As used in this specification, the term "or" includes any and all combinations of the relevant listed items. The term "any" is understood to include any possible combination of the referenced items, including "any one" of the referenced items. The term "any" is to be understood as including any possible combination of the appended claims, including "any" claims as referred to.

For consistency and convenience, directional adjectives may be used throughout the detailed description corresponding to the illustrated embodiments. Those of ordinary skill in the art will recognize that terms such as "above," "below," "upward," "downward," "top," "bottom," et cetera, may be used descriptively of the figures, and do not represent limitations on the scope of the invention, as defined by the claims.

The term "longitudinal" refers to a direction extending the length of a component. For example, the longitudinal direction of the shoe extends between a forefoot region and a heel region of the shoe. The terms "forward" or "anterior" are used to refer to the general direction from the heel region toward the forefoot region, and the terms "posterior" or "posterior" are used to refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, the component may be identified with a longitudinal axis and a longitudinal direction forward and rearward along the axis. The longitudinal direction or axis may also be referred to as a front-to-back direction or axis.

The term "transverse" refers to the direction extending the width of a component. For example, the lateral direction of the shoe extends between a lateral side and a medial side of the shoe. The lateral direction or axis may also be referred to as a lateral direction or axis or a medial-facing direction or axis.

The term "vertical" refers to a direction generally perpendicular to the lateral and longitudinal directions. For example, in the case of a sole lying on the ground, the vertical direction may extend upwardly from the ground. It should be understood that each of these directional adjectives may be applied to individual components of the sole. The term "upward" or "upwardly" refers to a vertical direction that is directed toward the top of the component, which may include the instep, fastening area, and/or throat of the upper. The terms "downward" or "downward" refer to a vertical direction, opposite the upward direction, that is directed toward the bottom of the component, and may generally be directed toward the bottom of the sole structure of the article of footwear.

An "interior" of an article of footwear, such as a shoe, refers to the portion of space occupied by a wearer's foot when the shoe is worn. "medial" of a component refers to a side or surface of the component that faces (or will face) the component in the assembled article of footwear or the interior of the article of footwear. "lateral" or "exterior" of a component refers to the side or surface of the component that is (or will be) away from the interior of the shoe in the assembled shoe. In some cases, other components may be between the medial side of the component and the interior of the assembled article of footwear. Similarly, other components may be between the lateral side of the component and the space outside of the assembled article of footwear. Furthermore, the terms "inwardly" and "inwardly" refer to directions toward the interior of a footwear component or article, such as a shoe, and the terms "outwardly" and "outwardly" refer to directions toward the exterior of a footwear component or article, such as a shoe. Furthermore, the term "proximal" refers to a direction that is closer to the center of the footwear component or closer to the foot when the foot is inserted into the article of footwear when the user is wearing the article of footwear. Likewise, the term "distal" refers to a relative position that is farther from the center of the footwear component or farther from the foot when the foot is inserted into the article of footwear when the user is wearing the article of footwear. Thus, the terms proximal and distal may be understood as providing generally opposite terms describing relative spatial locations.

While various embodiments have been described, the description is intended to be exemplary, rather than limiting, and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the embodiments. Any feature of any embodiment may be used in combination with or in place of any other feature or element in any other embodiment, unless specifically limited. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Further, various modifications and changes may be made within the scope of the appended claims.

While various modes for carrying out many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings within the scope of the appended claims. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and exemplary of the full scope of alternative embodiments, which will be structurally and/or functionally equivalent to the contained matter or otherwise apparent based on the contained matter, and not be limited solely to those explicitly depicted and/or described embodiments.

Claims

1. An article of footwear, comprising:

an upper including at least a first layer of a first material having a first melting temperature, the first layer having an interior surface facing a foot-receiving cavity formed by the upper and having an exterior surface facing away from the foot-receiving cavity;

a heel support device disposed in a heel region of the upper and including a body and at least one peg having a stem portion and a head portion, a first end of the stem portion being connected to the body and the head portion being disposed at a second end of the stem portion; wherein the body is disposed adjacent an inner surface of the first layer and the head is disposed adjacent an outer surface of the first layer; wherein the at least one pin comprises a second material having a second melting temperature that is lower than the first melting temperature; and wherein the head is formed by melting a second material of the pin at the second end, and

wherein the body of the heel support device comprises a lever and a base having a toothed inner edge comprising a series of notches.

2. The article of footwear according to claim 1, wherein the stem and head are a unitary, one-piece structure, the stem further comprising the second material.

3. The article of footwear according to claim 1, wherein the head, stem, and body are a unitary, one-piece structure, the stem and body further comprising the second material.

4. The article of footwear according to claim 1, wherein the first layer of the upper defines apertures that are spaced apart from one another in a first arrangement; and is also provided with

The at least one peg includes a plurality of pegs spaced from one another in the first arrangement and extending through apertures in the upper.

5. The article of footwear according to claim 4, wherein:

the first layer is an outer layer of the upper, the upper further comprising an inner layer, the foot-receiving cavity being on a medial side of the inner layer;

the aperture extending through the outer layer;

the heel support device is arranged between the inner layer and the outer layer; and is also provided with

The inner layer is disposed between the heel support device and the foot-receiving chamber.

6. The article of footwear according to claim 5, wherein:

the body including a central portion, a medial portion extending forward from the central portion on a medial side of the heel support device, and a lateral portion extending forward from the central portion on a lateral side of the heel support device;

wherein a first peg is integral with and extends outwardly from the central portion, a second peg is integral with and extends outwardly from the intermediate portion, and a third peg is integral with and extends outwardly from the lateral portion.

7. The article of footwear according to claim 6, wherein the heel support device including the central portion, the medial portion, the lateral portion, and the peg is a unitary, one-piece component.

8. The article of footwear according to claim 5, wherein:

the control lever having a central section, a medial side arm extending downwardly and forwardly from the central section on a medial side of the heel support device, and a lateral side arm extending downwardly and forwardly from the central section on a lateral side of the heel support device;

the base also has a middle base arm connected to the middle side arm of the lever, a lateral base arm connected to the lateral side arm of the lever, and a center section connecting the middle base arm to the lateral base arm; and is also provided with

The first peg extends outwardly from the central section of the lever, the second peg extends outwardly from the medial side arm of the lever or from the medial base arm, and the third peg extends outwardly from the lateral side arm of the lever or from the lateral base arm.

9. The article of footwear according to claim 8, wherein:

the control lever comprises a series of slats;

each slat in a series of slats extends in the central section, medial side arms, and lateral side arms; and is also provided with

The first peg extends outwardly from one of a series of slats and the fourth peg extends outwardly from a central section of the base.

10. The article of footwear of any of claims 8-9, wherein:

the lever being biased to an unloaded position and resiliently flexed under the application of force to a loaded position in which the lever is closer to the base than in the unloaded position, storing potential energy that returns the lever to the unloaded position upon removal of the application of force;

the vamp is connected with the control rod through the first bolt so as to move together; and is also provided with

The ankle opening of the upper extends more rearward and downward when the lever is in the loaded position than when the lever is in the unloaded position.

11. The article of footwear of claim 1, wherein the head depicts at least one of a number, letter, symbol, logo, object, or design.

12. A method of manufacturing an article of footwear, the method comprising:

obtaining a heel support device having a peg comprising a stem, wherein the heel support device further comprises a control rod and a base having a toothed inner edge comprising a series of notches;

extending the stem through and protruding from the first layer of the upper; and

after the stem protrudes from the first layer, a head is formed at an end of the stem, wherein forming the head includes melting an end of the stem.

13. The method of claim 12, wherein forming the head bonds the head to the first layer.

14. The manufacturing method according to any one of claims 12 to 13, wherein forming the head portion includes pressing a heating tool against an end portion of the stem portion to melt the end portion.

15. The method of claim 14, wherein the heating tool has a mold surface that molds the head, and the method of manufacturing further comprises:

the heating tools are selected from a set of heating tools, each having a mold surface with a different shape depicting at least one of a number, letter, symbol, logo, object, or design, or having a different surface texture.

16. The method of manufacturing of claim 15, wherein selecting the heating tool is responsive to a request for a particular shape or a particular surface texture of the head; and wherein the mold surface of the selected heating tool has the particular shape or particular surface texture requested.

17. The manufacturing method according to any one of claims 12-13, wherein the head protrudes through a hole in the first layer, and the head is larger than the hole.

18. The method of manufacturing of claim 14, wherein the head protrudes through an aperture in the first layer and the head is larger than the aperture.

19. The method of manufacturing according to any one of claims 12-13, wherein the upper further comprises a second layer, the method further comprising:

the heel support device is placed between the first and second layers prior to forming the head.

20. The method of manufacturing of claim 14, wherein the upper further comprises a second layer, the method further comprising:

21. The method of manufacturing according to claim 19, wherein the placement of the heel support device between the first layer and the second layer of the upper is through an opening between the first layer and the second layer; and the manufacturing method further comprises:

after placing the heel support device between the first layer and the second layer, the opening is closed.

22. The method of manufacturing according to claim 20, wherein the placement of the heel support device between the first layer and the second layer of the upper is through an opening between the first layer and the second layer; and the manufacturing method further comprises:

23. An article of footwear, comprising:

an upper defining apertures spaced apart from one another in a first arrangement;

a heel support device connected to a heel region of the upper and having pegs spaced apart from one another in a first arrangement and extending through apertures in the upper; and

wherein the pegs are fixed at the surface of the vamp, each of the pegs includes a shaft portion and a head portion integrally constructed with the shaft portion, and the head portion is formed by melting one end portion of the shaft portion, and

wherein the heel support device comprises a lever and a base having a toothed inner edge comprising a series of notches.

24. The article of footwear according to claim 23, wherein:

the upper including an interior layer and an exterior layer, and defining a foot-receiving cavity on a medial side of the interior layer;

the aperture extending through the outer layer, the heel support device being disposed between the inner and outer layers; and is also provided with

25. The article of footwear of claim 23 or claim 24, wherein:

The shaft portion extending through one of the apertures of the upper; and is also provided with

The head is bonded at a surface of the upper.

26. The article of footwear of claim 25, wherein the head depicts at least one of a number, letter, symbol, logo, object, or design.

27. The article of footwear according to claim 23 or claim 24, wherein the heel support device comprises: a central portion, a medial portion extending forward from the central portion on a medial side of the heel support device, and a lateral portion extending forward from the central portion on a lateral side of the heel support device; and is also provided with

Wherein a first peg is integral with and extends outwardly from the central portion, a second peg is integral with and extends outwardly from the inner portion, and a third peg is integral with and extends outwardly from the outer portion.

28. The article of footwear according to claim 27, wherein the heel support device including the central portion, medial portion, lateral portion, and peg is a unitary, one-piece component.

29. The article of footwear according to claim 27, wherein:

The control lever having a central section, an inner side arm extending downwardly and forwardly from the central section on the medial side of the heel support device, and a lateral side arm extending downwardly and forwardly from the central section on the lateral side of the heel support device;

the base also has an inner base arm connecting the inner arm of the control lever, an outer base arm connecting the outer arm of the control lever, and a center section connecting the inner base arm and the outer base arm; and is also provided with

The first peg extends outwardly from a central section of the lever, the second peg extends outwardly from an inner arm or from an inner base arm of the lever, and the third peg extends outwardly from an outer arm or from an outer base arm of the lever.

30. The article of footwear according to claim 29, wherein:

the control lever comprises a series of slats;

each slat in the series of slats extends in a central section, an inner side arm, and an outer side arm; and is also provided with

The first peg extends outwardly from one of the series of slats and the fourth peg extends outwardly from the central section of the base.

31. The article of footwear of any of claims 29-30, wherein:

The vamp is connected with the control rod through a first bolt so as to move together; and is also provided with

The ankle opening of the upper extends further rearward and downward when the lever is in the loaded position than when the lever is in the unloaded position.

32. A method of manufacturing an article of footwear, the method comprising:

placing a heel support device between an inner layer of the upper and an outer layer of the upper, wherein the heel support device includes at least one peg extending outwardly toward the outer layer, a lever, and a base having a toothed inner edge including a series of notches;

inserting at least one peg of the heel support device through an outer layer of the upper such that the at least one peg extends through the outer layer and is exposed at an outer surface of the outer layer; and

after inserting at least one peg of the heel support device through the outer layer of the upper, securing the at least one peg to an outer surface of the outer layer, wherein

The at least one peg comprises a plurality of pegs and the outer layer of the upper comprises a plurality of holes;

the pegs are spaced from each other in a first arrangement;

the holes are spaced from each other in the first arrangement such that the holes are aligned with the pegs;

Securing the at least one peg to an exterior surface of an exterior layer of the upper includes bonding the at least one peg to an exterior surface of the exterior layer;

bonding the at least one pin to the outer surface of the outer layer includes pressing a heating tool against an end of the at least one pin at the outer surface of the outer layer to melt the end against the outer surface of the outer layer; and is also provided with

The heating tool has a mold surface that forms a head of at least one pin at an outer surface of the outer layer and presses the heating tool to melt the end to produce the head.

33. The manufacturing method of claim 32, further comprising:

34. The method of manufacturing of claim 33, wherein selecting the heating tool is responsive to a requirement for a particular shape or a particular surface texture of the head; and is also provided with

Wherein the mold surface of the selected heating tool has a desired specific shape or specific surface texture.

35. The method of manufacturing according to any one of claims 32-34, wherein placing the heel support device between the inner layer of the upper and the outer layer of the upper is through an opening between the inner layer and the outer layer; and the manufacturing method further comprises:

after placing the heel support device between the inner and outer layers, the opening is closed.

36. An article of footwear, comprising:

an upper having at least a first layer of pliable material disposed about at least a portion of the foot-receiving cavity;

a heel support device disposed adjacent a first side of a first layer of the foot-receiving chamber, the heel support device comprising a control rod and a base having a toothed inner edge comprising a series of notches;

a peg extending from a first end connected to the heel support device to a distal end spaced apart from the heel support device; wherein the peg passes through an aperture provided in the first layer and extends to a second side of the first layer;

wherein the peg comprises a shaft portion and a widened head portion disposed at a distal end of the peg;

wherein the widened head portion is integrally constructed with the shaft portion and the widened head portion is formed by melting a distal end of the pin; and is also provided with

Wherein the width of the widened head is greater than the width of the aperture.